Process for forming novel spiral compositions

ABSTRACT

A method and apparatus are provided that allows two or more compositions to be filled with a spiral configuration into a single container. Each product may have completely different chemical and physical properties, and each product may have a different function and purpose. The method includes providing at least two compounds, arranged in separate storage bins each having a pump and a hose attached thereto; rotating a container, for receiving a resulting product formed by the at least two compounds, into position relative to a support and alignment funnel; pumping the at least two compounds through the respective hoses into a nozzle assembly having at least two nozzles for filling the container; and combining predetermined amounts of each of the at least two compounds for creating the resulting product housed in a single container, wherein the resulting product has the at least two compounds formed in a spiral configuration.

This is a continuation of application Ser. No. 09/481,968 filed on Jan.12, 2000.

BACKGROUND OF THE INVENTION

1. Area of Art

The present invention relates to making multi-product fills forsubstantive and decorative purposes. In particular, the presentinvention relates to novel ways to fill containers with separate kindsand types of cosmetics, whereby an enhanced and durable spiralconfiguration of multi-phase (heterogeneous) products may be made, inaddition to other novel product configurations.

2. Description of the Prior Art

A survey of existing products on the market reveals the multiple effortsthat have been made to create visually appealing product configurations,and the containers that house them, which serve to preserve a desiredvisual appeal. Likewise, in addition to mechanical attempts to solvethese problems, chemical solutions have also been attempted; however,the lack of commercial success in this field points to an on-going andlongstanding need.

Conventional attempts at making a two-or-more phase product in onedispensing container have proven difficult and sometimes impossible dueto chemical reactions or product instability (i.e., reacting with eachother). What has not been adequately accomplished, or developed to date,is a system based on the chemicals themselves and the system chemistryand incompatibility—for example, putting water and oil together.Likewise, after reviewing thousands of products, only a few personalcare cosmetics with two-or-more phases in one dispensing container wereuncovered.

To understand why known systems have not been able to address theaforementioned problems effectively, further background is offered forconsideration to explain the nature of the problem, and why it has beensolved by the instant teachings.

Cosmetic materials generally contain various types of coloringmaterials, such as pigments and dyes. Such coloring may materialscontain materials derived from raw materials as maskimg agents forcovering coloring. In some cases, these masking agents are included forthe purpose of providing a particular effect in relation to skin makeup.Such effect is a positive function of these coloring materials.

Because consumers have increasingly demonstrated a diverse sense ofappreciation in regard to the value of cosmetic materials, such cosmeticmaterials are now required to possess additional merits related to theirintrinsic appeal as objects of beauty. This appreciation is incomplement with providing pleasure in use, as well as the basicfunctions of being suitable for make-up, and so forth. In other words,today's cosmetics must look good and work well to satisfy the needs ofthe consumers.

Historically, the preparation of two-or-more differently coloredproducts has been challenging. Even in cosmetics such as basiclipsticks, to produce a two-tone or multi-colored effect on the lipsrequired innovation. In such instances, to achieve the desired blendingeffect, one color had to be applied to the lips as a base and the othercolor or colors superimposed thereon for contrast. The desired finaleffect was then achieved by blending the superimposed colors on the lipsitself.

Likewise, attempts have been made to produce a unitary lipstick having aplurality of colors by assembling several individual segments in anadjacent spaced relationship, and thereafter compressing the segmentstogether to form a unitary lipstick mass. Such lipsticks, however, havemet with limited commercial success. One reason may be that theselipsticks have been more difficult and expensive to produce thanconventional one-color lipsticks. In practice, of course, lipsticks thatare formed by molding segments of different colors into a singlemulti-colored tube are usually applied to the lips by using the singlecolor of each segment such that these lipsticks merely offer theconvenience of two separate colors in one unitary mass.

Known disclosures thus highlight that the concept of a dual-phase ormulti-phase cosmetic composition being quite interesting inasmuch assuch a composition has a potential for combining two or more functionalcosmetic aspects into a single product that may be applied to a subject.However, with any such multi-functional, multi-phase cosmeticcomposition, it is obviously important that the formed product befunctional and effective and that such be maintained, preserved, andusable over a reasonable product life span. This difficulty has not beenovercome by known disclosures.

Another largely unaddressed issue is containing and packaging amulti-phase cosmetic composition. Here, it is desirable that each of thephases comprising the total product be dispensed into a container suchthat the respective phases are generally maintained separately, remainstable, and that in viewing the product, each phase as packaged isvisually distinct. Of principal concern is that during the proposed lifeof a multi-phase cosmetic product, respective phases comprising thetotal product do not blend and mix together such that the total productin the end is nearly or substantially homogeneous. In addition, incontaining a multi-functional, multi-phase cosmetic composition, it isimportant that the respective phases comprising the composition bedispensed in a manner such that the particular phases are present andoccur throughout the final product. It is also important that ingathering a single application from a container, a subject is likely togather an adequate amount of each respective phase.

At the root of these several matters is the idea that cosmetic productsrely on color to provide beauty enhancement. Thus, beauty aids such asfoundation, blush, mascara, brow products, and the like, rely on colorenhancement provided by these products for effectiveness. In view of thecriticality of color in such applications, it is desirable to presentthe cosmetic product, which is ultimately applied to the face or otherparts of the body to highlight that color, in a way that emphasizes itscolor. In the past, such cosmetic products, if visible at all, werepresented as a colored composition. Those skilled in the cosmetic artsappreciate that if the color of the cosmetic composition could bepresented in a more dramatic manner, the product would be more desirableto the purchaser.

For example, presenting the color in the form of a spiral, helix,swirled pattern, or the like, against a background of a clear orcolor-contrasted liquid, dramatically emphasizes the attractiveness ofthe color of the cosmetic beauty aid.

It would be relatively simple to produce an oil-based pigment phase in aclear aqueous phase, or vice versa. The immiscibility of the two phaseswould permit the production of a cosmetic product in which the abovedesired, highly attractive packaging could be provided. However, theinclusion of an oil-based phase would be undesirable for at least tworeasons. First, it would be difficult to combine the immiscible phasesto form the complete cosmetic composition. Second, even if the twoimmiscible phases could somehow be combined, the product, containing anon-water-soluble phase might be difficult to remove.

Ideally, a two-phase composition should include a color phase and clearor color-contrasted gel phase that are miscible. However, when attemptswere made to produce such a product in the past, a two-phase compositionwas obtained in which the color phase bled into the gel phase, producinga product that was aesthetically unattractive.

Thus, cosmetic products have not been produced in which a color phase,highlighting the tint or color of the cosmetic composition, is disposedas a discrete color phase against a background of a clear orcolor-contrasted gel.

An emulsion is known to be a dispersed system comprising at least twoimmiscible liquid phases (Remington's Pharmaceutical Sciences, 18thEdition, 1990). The emulsion's immiscible liquid phase is composed ofdroplets between 0.005 to 2000 microns in diameter, although the rangeof droplet diameters may be narrower (e.g., between 0.1 to 100 microns).Emulsions are known to be thermodynamically unstable. It is believedthat the free energy associated with the high surface area of smalldroplets is reduced when these droplets coalesce into large droplets ofless surface area. To minimize droplet coalescence, it is known that anemulsifying agent can be added to form a thin film about each droplet ofimmiscible liquid in the emulsion (Remington's Pharmaceutical Sciences,18th Edition, 298-309, 1990).

Stable emulsions containing silicones of two or three phases arewell-known. The low surface tension of silicone promotes thin filmformation which stabilizes emulsions. Lower alkyl (C₁-C₄) andamino-substituted polysilaxanes (silicones) are used because of theirinsolubility in polar and non-polar liquids such as water and oils.Seldom used are the cyclic silicones, such as diphenylmethicone, becauseof their oil solubility which causes the cyclic silicones to dissolve inthe oil phase of the emulsion rather than forming a distinct phase.

Silicone emulsions have been used in a number of products. In cosmetic,pharmaceutical and skin preparations, a fat paste-like emulsion ofdecamahylpentasilaxune, poly(oxyethylene stearate), water and sorbitanmonostearate has been used (Thimineur R. J. & Traver F. J., DE3,045,083). In personal-care formulations, such as water-based hairconditioners, water in silicone emulsion has been used (Gum, M. L.,W08S/03641/AI). In formulations for polishes, an emulsion ofdimethylsiloxanes, naphtha hydrocarbons, emulsifiers and water has beenused (Hill M. P. L. & Vandamme L. J R., DE 3,616,575 A1). Water-thinnedpaint emulsions have used silicones (Udalova A. V., et al.,LakokasMater, Ikh. Primen., 2:14-16). Waterproof sealant emulsions have usedsilicones (Saad W. T. & Stodgell R. F., U.S. Pat. No. 4,383,06; BaumanT. M., Freiberg A. L., U.S. Pat. No. 4,590,220).

The ordered phase of liquid crystal has many of the properties of thesolid state such as optical anisotropy and birefringence, which producespecial interference patterns that can be detected using across-polarizing microscope. Liquid crystals also have the mechanicalproperties of liquids. Because the crystals have only partial rotationalor translational freedom the liquid crystals exist in a mesophase state(Intro to Liquid Crystals, Priestly E. B., et al., eds., Plenum Press,N.Y. 1976).

Liquid crystals known as lyotropic liquid crystals may spontaneouslyform when the concentration of oils in an oil-water emulsion is at aparticular concentration. (See, e.g., Marland J. S. & Mulley B. A., J.Pharm. Pharmocol. 1971, 23(8): 561-572). Lyotropic liquid crystalformation is commonly observed in a wide variety of emulsions and suchliquid crystals are known to be unstable.

The only significant attempt among the prior art to address the problemsolved by the teachings of the present invention was a hair gel where awhite product was filled inside of a clear gel. The product was filledusing a two-step process. First, the clear gel was filled with an Arencotube, and then in a modified registration station, the spiral was filledwith a diving nozzle and a peristaltic pump.

Formation of the spiral required spinning the tube of clear gel and thensubmerging the nozzle to the bottom of the tube. While the nozzle wasthen lifted up, the peristaltic pump started and operated until thenozzles came close to the top of the clear product. The next step wasstopping and reversing to stop the flow of the white product.

Known spiral fills (for example sold by Estee Lauder⁷, Lapraire⁷, ErnoLazlo⁷ and Revlon⁷), or more elaborate designs in clear gel, are pricedat between $50.00 and $100.00, and require two-step processes, both ofwhich urge strongly against their industrial efficacy. Their respectiveshelf-lives are also dubious.

Likewise, toothpaste-tube filling technology works by simultaneouslyfilling tubes in straight lines that show through transparent windows inthe sides of the tubes. While such efforts are dictated by ornamentalconstraints, no known methods can perform the process in fewer than twosteps.

Finally, there are liquid crystals that form at only certaintemperatures known as thermotropic liquid crystals. This type of liquidcrystal is quite stable, but has not been used to solve the problemsaddressed by the teachings of the present invention.

U.S. Pat. No. 4,335,103 to Barker et al. (the '103 patent) discloses atwo-phase cosmetic cleansing cream composition that includes twoseparate and stable cosmetic composition phases that, when inter-mixed,yield a cleansing composition that is applicable to the face and otherparts of the body. This composition comprises a first cleansing-creamphase composition that includes an oil, a thickening agent, anemulsifier, and water.

The second phase, a gel phase, comprises water or a water-solublematerial and a thickening agent. The two-phase cosmetic cleansing creamcompositions are combined in a swirl-like or marble-like pattern withina container such that the cream hard-gel phases are generally stable,separate, and visibly distinct.

Although the teachings of the '103 patent represents an advance in theart, it does not emphasize a color phase. Colorants easily migrate. Assuch, the absence of a teaching in the prior art of non-bleeding phasesestablish the absence in the art of a two-phase cosmetic composition inwhich the color-phase composition highlights the critical emphasis ofthe composition.

Likewise, conventional cosmetic vehicles for skin moisturization delivermoisture to the skin only on the initial application of the cosmeticmoisturizer. The need for a cosmetic, dermatologic or medicinalmulti-phasic vehicle that will, in addition, provide sustained skinmoisturization while blocking skin moisture loss has been long felt.There has also been a need for a multi-phase vehicle that can be used toprovide water-soluble and lipid-soluble active ingredients, such asvitamins, plant extracts, antioxidants, proteins, polymers, oils and thelike. Most cosmetic vehicles consist of emulsions. In sum, there areneeds for two or more types of cosmetic products housed within the samecontainer.

In contrast to known systems, the teachings of the present inventionaddress and overcome these long felt needs by providing, instead of twoor more different products, one product (or a unitary composition housedin a single container) with multiple functions and differentappearances.

The present inventors have yet to see something functional like this onthe market. There are some products with somewhat similar concepts, butnot functionally implemented. Attempts ranging from products withfloating materials that have no purpose to spirals that degrade whenmoved, or merely constitute ornamental fillers, show the need for thepresent invention. Accordingly, the instant system combines chemicalfunctionality and a visually appealing product to overcome the drawbacksof the prior art.

OBJECTS AND SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide aprocess and apparatus to overcome the drawbacks of the prior art.

Additionally, it is an object of the present invention to provide aprocess and apparatus for generating a dual-phase or multi-phase productwhereby each phase maintains certain chemical and physical propertiesthat makes each phase stable and gives each phase the ability toco-exist with the other.

Another object of the present invention is to provide a solution to theproblem of having multiple functions in a single product by creating astable and extremely functional product.

Briefly stated, an apparatus is provided that can have two or moreproducts filled in the same container having a swirl-like pattern. Eachproduct can have completely different chemical and physical properties.Thus, each product can have a different function and purpose.

According to an embodiment of the present invention, there is provided amethod of forming spiral compositions, comprising the steps of:providing at least two compounds, arranged in separate storage bins eachhaving a pump and a hose attached thereto; rotating a container, forreceiving a resulting product formed by the at least two, into positionrelative to a support and alignment funnel; pumping the at least twocompounds through the respective hoses into a nozzle assembly having atleast two nozzles for filling the container; and combining predeterminedamounts of each of the at least compounds for creating the resultingproduct housed in a single container, wherein the resulting product hasthe at least two compounds formed in a spiral configuration.

According to an embodiment of the present invention, there is providedan apparatus for filling a container with a resulting product having atleast two compositions formed in a spiral configuration, comprising: anozzle assembly having at least two nozzles coupled together in a closeconfiguration; at least two pumps for pumping each of the compositionsstored in separate composition storage bins each interconnected by asuction hose to each pump; at least two hoses interconnected to thenozzles and the pumps; a support and alignment funnel coupled to theapparatus for supporting the container to be filled in an uprightposition; a drive motor coupled to the nozzle assembly adapted to movethe nozzle assembly in a vertical direction during filling of thecontainer; and a spinning motor coupled to a spinning puck that supportsthe container and rotates the container during filling of the container.

DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front view of an apparatus that performs theprocess of creating at least a dual-phase spiral product according to anembodiment of the present invention;

FIG. 2 illustrates a rear view of an apparatus having a controlmechanism that performs the process of creating at least a dual-phasespiral product according to an embodiment of the present invention;

FIG. 3 illustrates a cross-sectional view of three examples of nozzleconfigurations according to an embodiment of the present invention; and

FIG. 4 illustrates a side view of an example of an opening of a nozzleassembly according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present inventors have discovered that, as discussed above, oneapproach not adequately explored to date involves a new delivery systemusing a toothpaste-like filling concept, with one of the two usual stepseliminated, and applying the same to a desired personal care product.This invention allows the generation of a wide variety of products,especially those nearly impossible to formulate with chemicals oralternate systems (i.e., ascorbic acid or clear shower gel with a highlevel of silicones).

The present inventors have further discovered that dual-phasecompositions are most favorably disposed within single containers formany cosmetic industry applications. In solving the problems discussedabove with respect to creating chemically integrable products, issueswith respect to filling containers with the resulting compositions havegenerated their own respectively innovative solutions.

Namely, in lieu of rotating tubes, top and bottom filling schemes, andcontrol rate of flow issues, the present inventors have fabricated aone-step process that allows the filling of a product having two or morecompounds with ratios and patterns that are quite variable, yet makes adurable resulting product.

Likewise, the flexibility achieved by the instant teachings has resultedin a novel enhanced spiral fill that overcomes the pitfalls created asartifacts of the toothpaste-based processes. This approach enables thedispensing of the product in a more uniform and aesthetically-pleasingfashion, in addition to an improved display.

As mentioned below, the most studied prior art attempt to address theproblem solved by the teachings of the present invention was a hair gelwhere a white product was filled inside of a clear gel. The product wasfilled using a two-step process. First, the clear gel was filled with anArenco tube, and then in a modified registration station, the spiral wasfilled with a diving nozzle and a peristaltic pump.

According to this disclosure, formation of the spiral required spinningthe tube of the clear gel and then submerging the nozzle to the bottomof the tube. While the nozzle was then lifted up, the peristaltic pumpstarted and operated until the nozzle came close to the top of the clearproduct. The next step was stopping and reversing the flow of the whiteproduct. In addition to the cost factors, high degrees of mechanical andsystemic failures resulted from this two-step process.

Conventional spiral fills have been subject to these same constraints,and by way of further example, known designs in clear gel are priced atbetween $50.00 and $100.00, per container and require two-stepprocesses, both of which urge strongly against their industrialefficacy. This is in addition to the fact that such disclosure haslittle durability.

Similarly, and in contrast to the instant teachings, toothpaste-tubefilling technology works by simultaneously filling tubes in straightlines that show through transparent windows in the sides of the tubes.While such efforts are dictated by ornamental constraints, neithermethod can perform the process in fewer than two steps.

FIG. 1 illustrates a front view of an apparatus that performs theprocess of creating at least a dual-phase spiral product according to anembodiment of the present invention. A drive motor dive assembly 101 isshown, which is coupled to the filling nozzle assembly 111. The drivemotor dive assembly 101 is adapted to move the filling nozzle assembly111 in a vertical direction for filling a container with the resultingproduct. FIG. 1 illustrates a nozzle assembly 111 having two nozzles,but, there may be more than two nozzles incorporated into a nozzleassembly 111 depending upon the resulting product to be created. Thenozzle assembly 111 may be further supported by a nozzle supportassembly 105 coupled to the apparatus.

FIG. 1 also illustrates a spinning motor 113, arranged next to aspinning puck 115, that is underneath a support and alignment funnel100. The support and alignment funnel 100 and the spinning puck 115 holdup the container (or tube) during the filling process. The spinning puck115 is driven by the spinning motor 113, which provides the mechanicalcapability to rotate the spinning puck 115, thus rotating the container,during the filling process.

There are also pumps 107, 135 (see FIG. 2) for pumping each of thecompositions (that will form the resulting product) stored in separatecomposition storage bins through hoses 103, 109 that are interconnectedto the pumps (107, 135) and the nozzle assembly 111. The pumps may begear-type pumps, or piston-type pumps. Preferably, piston-type pumps areused because they provide a more precise delivery of the compositionsstored in the storage bins.

FIG. 2 illustrates a rear view of an apparatus having a controlmechanism that performs the process of creating at least a dual-phasespiral product according to an embodiment of the present invention. Thefirst pump 107 and a second pump 135 are shown at the rear of theapparatus. Connected to the pumps 107, 135 are suction hoses 127, 137,which are interconnected with the separate composition storage bins.

FIG. 2 illustrates a flow rate controller 121, 133 for controlling theflow rates of each of the pumps 107, 135. A fill-time timer 123 isprovided on the apparatus to determine the amount of time required tofully fill a container of the resulting product. There is also a spinspeed controller 117 on the apparatus to control the rotational velocityof the spinning puck 115. A dive and rise after fill speed controller119 allows the user to control the speed of the nozzle assembly 111 asit moves in the vertical direction before and after the fillingoperation. The control box for lifting and spinning 129 houses theelectronics and circuitry for controlling the spinning motor 113 and thedrive motor dive assembly 101. There is also a rise during fill speedcontroller 131 on the apparatus that allows the user to control thespeed of the nozzle assembly as it moves up in the vertical directionduring the filling operation.

FIG. 3 illustrates a cross-sectional view of three examples of nozzleopening configurations 300, 301, 302, each producing a dual-phasecomposition according to an embodiment of the present invention. Each ofthese three nozzle opening configurations 300, 301, 302 will produce aresulting product with different spiral configurations. The arrangementof the nozzle openings with the type of material to be dispensed may beof a variety of combinations, and FIG. 3 illustrates only threeexemplary samples.

FIG. 4 illustrates a side view of an example of an opening of a nozzleassembly 111 according to an embodiment of the present invention. Forexample, a clear gel may be dispensed from the center of the nozzle 400,while colored/contrast materials may be dispensed from the nozzleopenings on the sides 401, 402. Any suitable arrangement may be made inorder to produce a specific spiral configuration of the resultingproduct.

The compounds and compositions dispensed by the apparatus of the presentinvention are not limited to cosmetic and/or health care products. Anyliquid or semi-liquid compound may be dispensed from the storage bins,including different colored waxes for making candles having novel spiralconfigurations. Plastics and other polymer materials may also bedispensed, and novel spiral configurations may also be formed by theapparatus of the present invention using these materials.

Having described preferred embodiments of the invention with referenceto the accompanying drawings, it is to be understood that the inventionis not limited to those precise embodiments, and that various changesand modifications may be effected therein by one of ordinary skill inthe art without departing from the scope or spirit of the invention asdefined in the appended claims.

What is claimed is:
 1. An apparatus for filling a container with aresulting product having at least two compositions formed in a spiralconfiguration, comprising: a nozzle assembly having at least two nozzlescoupled together in a close configuration; at least two pumps forpumping each of the compositions stored in separate composition storagebins, each bin being connected to one of the pumps by a suction hose;hoses connecting the nozzles to the pumps; a support and alignmentfunnel coupled to the apparatus for supporting the container to befilled in an upright position; a drive motor coupled to the nozzleassembly adapted to move the nozzle assembly in a vertical directionduring filling of the container; and a spinning motor coupled to aspinning puck that supports the container and rotates the containerduring filling of the container.
 2. The apparatus for filling acontainer with a resulting product according to claim 1, wherein theresulting product is a dual-phase composition.
 3. The apparatus forfilling a container with a resulting product according to claim 1,wherein the resulting product is a multi-phase composition.
 4. Theapparatus for filling a container with a resulting product according toclaim 1, wherein the resulting product is at least one of a facialcosmetic treatment and a cosmetic treatment for the body.
 5. Theapparatus for filling a container with a resulting product according toclaim 1, wherein the resulting product is a cationic personal careproduct.
 6. The apparatus for filling a container with a resultingproduct according to claim 1, wherein the resulting product is anon-ionic personal care product.
 7. The apparatus for filling acontainer with a resulting product according to claim 1, wherein theresulting product is a body gel.
 8. The apparatus for filling acontainer with a resulting product according to claim 1, wherein atleast one of the two compositions is a wax.
 9. The apparatus for fillinga container with a resulting product according to claim 1, wherein theat least two pumps are gear pumps.
 10. The apparatus for filling acontainer with a resulting product according to claim 1, wherein the atleast two pumps are piston pumps.
 11. An apparatus for filling acontainer with at least two compounds, said apparatus comprising:storage bins for storing the compounds; means in flow communication withthe bins for pumping each of the compounds from said bins; a nozzleassembly having a plurality of nozzles, the nozzles being in flowcommunication with the pumping means; first support means coupled to theapparatus for supporting the container in an upright position; andsecond support means disposed adjacent the container for supporting aturning motion thereof, wherein the apparatus is configured to produce aresulting product that is at least a dual-phase composition having agenerally swirled, spiral configuration.
 12. The apparatus of claim 11,wherein the means for pumping is selected from the group consisting ofgear pumps and piston pumps.
 13. The apparatus of claim 11, wherein theresulting product is a candle, or a composition selected from the groupconsisting of a facial cosmetic treatment, a cosmetic treatment for thebody, a cationic personal care product, a non-ionic personal careproduct, a body gel, and combinations thereof.
 14. The apparatus ofclaim 13, wherein the resulting product has more than two distinctphases.
 15. The apparatus of claim 13, wherein the compounds areselected from the group consisting of a wax, a gel, a cream, and aplastic.